Why Condensate Recovery System?When steam is used for indirect heat transfers in heat exchangers, reactors and other indirect heating equipment, it gives off its latent

(useful) heat to the process and converts itself into a liquid form known as condensate.

High pressure condensate is at almost the same pressure as steam and still contains around 15 to 20% heat of the fuel. This heat, if

recovered, can reduce fuel consumption to the extent of 20%.

TCRSTCRS

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STEAM ENGINEERING

A Thermax Group Company

What is TAFS?When high pressure condensate is discharged from steam traps into low pressure

condensate return lines, the excess energy is released in the form of flash steam. This flash

steam can be used to heat boiler feed water or for low pressure steam applications.

Technical SpecificationsMaterial of Construction

Body & Nozzles ASTMA 106Dished Ends IS2062 Gr.B/SA285

Design Specifications

Design Code ASME BPVC Sec VIII Div IDesign Pressure 14kg/cm2(g) Design Temperature 200OCHigher design/ operating pressure available on request

N1

N5

N2

C

B A

N6

N3

N4

INSULATION50 THK.

SUPPORTING COLUMNS75 x 40 - MEDIUM SECTION - 3 NOS.

CONNECTOR

Models & Dimensions

TAFS 150 TAFS 200 TAFS 300 TAFS 350

A 1510 1610 1660 1810B 1250 1335 1365 1505C 880 940 855 1075

N1 50 80 100 150N2 65 100 150 150

N3 40 40 50 50

N4 25 25 25 25

N5 15 15 15 15

N6 25 25 40 40

TM

End Connections

N1, N2, N3 flanged to ANSI B 16.5 Class# 150

N4, N5, Screwed BSP

Installation

The flash vessel should be installed in vertical position only, with flash

steam outlet at the top.

Features & Benefits

· Generates low pressure flash steam· Not covered under IBR· A dequately sized to minimize pressure drop

· Steam trap sized to handle condensate at low sure difference to be fitted at condensate outlet

· Designed with optimum separation velocity to get dry steam

What efficient condensate recovery system ensures

l High temperature feed water l Good quality boiler feed water

l Lower blowdown losses l Lower water treatment losses

The Thermax Condensate Recovery System (TCRS) is an integrated system comprising a flash steam generator, steam operated condensate transfer pump and deaerator unit with immersion tube.

This system efficiently recovers flash steam and hot condensate, and feeds them to the feed water tank through a well designed deaerator unit with immersion tube.

Selection Table Condensate Flash Model Size

(Kg/hr) (kg/hr) (mm NB)

850 200 TAFS 150 1502200 450 TAFS 200 200

4500 900 TAFS 300 300

7000 1150 TAFS 350 350

What is TADIT?It is an atmospheric de-aerator head designed to remove dissolved gases and oxygen from

the feed water, by properly mixing condensate, flash steam and cold make up water.

Solubility of oxygen and other dissolved gases decreases with rise in temperature, and

when they are released from the solution they exit through the air vent fitted on the de-

aerator head.

Features & Benefits

· Facilitates mixing of condensate, flash steam and cold make-up water

· Liberates dissolved gases and oxygen

· SS de-aerator head with SS immersion tube

Technical SpecificationsMaterial of Construction

Atmospheric De-aerator Head SS 304

Immersion Tube SS 304

Design Specifications

Design Pressure 5 kg/cm2(g)

Design Temperature 158OC

Models & Dimensions

TADIT 150 TADIT 200 TADIT 250 TADIT 300

A 440 490 500 500

B 370 420 475 525

C 185 210 235 265

D 175 200 210 225

N1 65 100 150 150

N2 50 80 80 100

N3 25 40 50 65

N4 15 15 15 15

N5 15 25 25 25

N6 150 200 250 300

Selection Table Condensate W/o flash Condensate with flash TADIT

(Steam Kg/hr) (Steam Kg/hr) (Model)

5000 150

10000 200

20000 Refer to Thermax for details 250

30000 300

N5

N1

N4

N3

N2

N6

N1 N2

N3

B

A

D

C

VACCUMBREAKER

CONNECTOR

THERMOSTATICVENT

DEAERATOR HEAD

TM

End connections

TADIT and nozzles N1, N2, N3 are provided with flanged end connection conforming to ANSI-B16.5 Class# 150, N4, N5

screwed BSP for airvent and recirculation.

Installation

The de-aerator head is mounted on the feed water tank on a flanged nozzle. Sealing gaskets are used above and below the

immersion tube flange.

Piping should preferably be of the same size as that of nozzles.

The flanged nozzle, supplied loose, is to be welded on the top of the FW Tank at a suitable location (refer GA drawing).

TM

What is TACTS?Thermax Automatic Condensate Transfer Pump - TACTSplus and TACTSultra

This pump is capable of pumping huge quantities of condensate effectively, by utilizing motive steam and consuming approximately 3 kg per 1000 kg of condensate. The condensate is one of the purest forms of water, with conductivity of the order of 3.5 ppm of TDS (5 s/cm).

The conductivity based level controller used in TACTS and TACTS is capable of sensing very low conductivity, even up to 0.35 ppm of TDS (0.5 s/cm). This controller makes TACTSplus and TACTSultra, FIT and FORGET pumps with no moving parts - thus ensuring zero maintenance.

Models & End ConnectionsModel Condensate Condensate Motive Receiver Pump Drain Over Trap line Pump

Inlet to receiver Outlet from Steam inlet Vent flow Vent

(N5, N6) pump (N3) (N12) (N7) (N4) (N8) (N15) (N14)

TACTS 200i 50 NB x 2 25 NB 15 NB 50 NB 25 NB. Scr BSP 40 NB 15 NB 15 NB

TACTS 300i 50 NB x 2 40 NB 15 NB 50 NB 25 NB. Scr BSP 40 NB 15 NB 15 NB

TACTS 400i 50 NB x 2 50 NB 15 NB 80 NB 25 NB. Scr BSP 40 NB 15 NB 15 NB

TACTS 500i 50 NB x 2 80 NB 15 NB 80 NB 25 NB. Scr BSP 40 NB 15 NB 15 NB End Connections: Ranged To ANSI B 165 class # 150

Technical Specifications

Features & Benefits

Material of construction

Receiver IS-2062 GR-B/ SA 285

Pump Body IS-2062 GR-B/ SA 285

Dished Ends IS-2062 GR-B/ SA 285

Nozzles (seamless) ASTM 106

Utilities requirement

Motive Steam TACTSplus 2-6 kg/cm2(g)

TACTSultra 2-10 kg/cm2(g)

Compressed Air 4-6 kg/cm2(g)

Electricity 230 Volts +5%

1 phase, AC 50 Hz

Design specifications

Design code ASME, BPVC Sec VIII Div 1

Design code 11 kg/cm2(g)

Design temperture 187OC

Discharge volume per stroke 25 litres

Steam consumption 3 kg/1000 kg of condensate

Ü Highest reliability and availability due to zero moving parts.2 ultraÜ High motive inlet pressure up to 10 kg/cm for TACTS . No need of pressure reducing till

210 kg/cm where low pressure steam is not available, hence saving of installation cost.

Ü High discharge of 50 litres per stroke - Discharges more volume/ stroke. Hence lesswear and tear of parts.

Ü High condensate temperature return-no cavitation problem as compared to electrical pump

Ü Skid mounted system - Easy to install.

Ü CE approved level controller - a stringent quality & design process followed in European market to ensure safe operation.

Ü Weather proof IP 65 design - suitable for outdoor installations.

Ü Energy efcient pump - steam trap drain and pump vent taken back to the receiver tank to minimize vent losses and save precious fuel.

Capacity chart for TACTSplus and TACTSultra

TACTS 200i TACTS 300i TACTS 400i TACTS 500i

Operating Inlet Total Lift/ Motive Pressure back pressure Plus Ultra Plus Ultra Plus Ultra Plus Ultra

2 2kg/cmg kg/cmg LPH LPH LPH LPH LPH LPH LPH LPH

2 0.5 1100 1190 2380 2860 3315 3790 5150 5400

1.0 1035 1150 2075 2550 2910 3460 4355 4520

0.5 1180 1260 2500 3000 3505 4080 5655 5980

3 1.0 1140 1200 2335 2770 3335 3830 4850 5100

1.5 1110 1170 2170 2560 3130 3600 4670 4840

2.0 1030 1050 1920 2320 2905 3410 4250 4350

0.5 1240 1300 2625 3100 3995 4290 5915 6390

1.0 1170 1240 2480 2920 3800 4090 5275 5510

4 1.5 1135 1200 2240 2670 3455 3790 4905 5200

2.0 1060 1090 2040 2460 3145 3520 4160 4570

3.0 890 940 1765 2090 2670 2880 2530 2810

1.0 1215 1270 2560 3030 4040 4290 5570 5830

5 1.5 1165 1230 2285 2760 3815 3950 5190 5480

2.0 1095 1130 2170 2560 3385 3600 4342 4743

3.0 955 980 1940 2230 2945 3040 3140 3260

1.0 1240 1300 2665 3130 4235 4460 5745 6090

1.5 1190 1250 2430 2830 3900 4070 5415 5700

6 2.0 1100 1150 2260 2650 3479 3670 4600 4880

3.0 970 1020 1995 2340 3009 3170 3430 3620

4.0 960 990 1710 1980 2520 2630 3300 3530

1.0 1320 3210 4210 6310

1.5 1270 2890 4170 5900

7 2.0 1180 2720 3720 5000

3.0 1050 2440 3280 3930

4.0 1020 2030 2680 3630

1.0 1340 3280 4320 6400

1.5 1280 2940 4260 6070

8 2.0 1200 2780 3770 5100

3.0 1070 2520 3380 4200

4.0 1040 2080 2720 3710

1.0 1350 3340 4420 6510

1.5 1290 2980 4340 6210

9 2.0 1220 2840 3820 5190

3.0 1100 2600 3460 4440

4.0 1060 2120 2760 3780

1.0 1370 3400 4510 6620

1.5 1310 3020 4410 6340

10 2.0 1230 2890 3850 5270

3.0 1120 2660 3540 4647

4.0 1080 2150 2800 3850

ultra

TAC

TS

plus

TAC

TS

For the pump operating without compressed air option, the condensate displacement capacity has to be veried from HO

In view of our constant endeavour to improve the quality of our products, we reserve the right to alter or change specifications without prior notice. All photographs shown in this publication are representative in purpose, and to be used for reference only. For actual details and specifications, please refer to Thermax offer document.

For more information, please get in touch with your nearest Thermax representative. You can also mail us at SteamEngineering@thermaxglobal.com or visit us at : www.thermaxglobal.com.

CRS scheme

Advantages of CRS

l Pure form of condensate l Less blowdown

l Less chemical l Less fuel consumption

Case study

Savings Calculations

FLASH STEAM GENERATION

Steam generation (kg/hr) 4000

Total condensate load (kg/hr) 3500

Pressure of condensate (kg/cm2) 8

Pressure of flash steam required (kg/cm2) 1

Fuel used FO (Liquid)

CV of fuel 9650

Flash steam generated (kg/hr) 376.22

Effective temperature of feed water

Temperature of feed water (Deg C) 30

Temperature of condensate (Deg C) 90

Effective temperature of feed water (Deg C) 83.40

ANNUAL SAVING

Boiler efficiency % 80.00

Saving in fuel/hr ` 27.67

Saving in fuel/ annum ` 215829.12

Rate of fuel ` 20.00

Annual saving (Lac) ` 43.17

Ver.

2 -

Jun

2020

Publication No. : SSBU/2015/SE/006

Steam Engineering